Tailgate structure for receiving supplemental tailgate

ABSTRACT

A tailgate structural configuration accommodates the housing of a supplemental tailgate internally within the tailgate. The tailgate is formed with an outer panel and an inner panel to define an internal cavity. The upper portion of the tailgate includes a C-channel frame member connected to both the inner and outer panels to support guide tubes telescopically housing the supplemental tailgate. To enhance structural stability, the tailgate further includes one or two transversely oriented strainers having formed therein flanged depressions or openings for the passage of the guide tubes vertically therethrough. Each guide tube is affixed to a mounting bracket that is detachably connected to the C-channel to support the guide tube within the tailgate. Positioning pins mounted on the mounting bracket affixed to the guide tubes engage locator holes in the C-channel for positioning the supplemental tailgate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims domestic priority on U.S. Provisional PatentApplication Ser. No. 60/743,277, filed on Feb. 10, 2006, and entitled“Modified Tailgate to House a Supplemental Tailgate”, the contents ofwhich are incorporated herein by reference. This application is adivision of U.S. patent application Ser. No. 11/358,229, filed Feb. 21,2006, and now granted as U.S. Pat. No. 7,234,749.

FIELD OF THE INVENTION

This invention relates to the utilization of a supplemental tailgateapparatus housed with the tailgate of a pick-up truck and, moreparticularly, to structural modifications made to the tailgate assemblyto receive a supplemental tailgate apparatus for deployment therefrom.

BACKGROUND OF THE INVENTION

Conventionally, pickup trucks include a tailgate at the back of a bedthat closes off a cargo box. Often times, the truck bed is not longenough to hold the cargo, so truck bed extenders have been developed.The truck bed extenders work in conjunction with the open tailgate inorder to provide additional length to the bed. Some of the bed extendersmount to the outside of the tailgate or to the box itself, which may beconvenient for deployment, but they tend to interfere with cargo spacein the box since the bed extender, when not in use, protrudes into thebox. Moreover, it is typical for the vehicle operator to employ theextender only occasionally, so it is generally undesirable to have theextender exposed at all times, which detracts from the attractiveness ofthe vehicle.

Additionally, it is sometimes desirable to have an extender that canprovide other functions in addition to a bed extender, such as a boxextender function—an upwardly extending structure from the rearmost edgeof an open tailgate that mimics the function of a closed tailgate. Sucharrangements are particularly useful for carrying a load that is longerthan the bed, but needs rearward support, such as provided by a closedtailgate, in order to prevent the load from falling rearwardly off thepick-up truck. Again, though, typical box extenders that provideadequate functionality are externally mounted and not only detract fromthe vehicle appearance when not in use but also require changes to thebox for mounting such extenders. Also, most of these types of extendersare very cumbersome to deploy and later stow away, thus beingundesirable for the operator to use. Such functions may be provided withsimple ergonomic operation of the assembly, while still allowing for anattractive appearance for the vehicle when the extender is stowed duringperiods of non-use. Thus, while the exterior mounted extenders may beable to perform multiple functions, they still suffer from the drawbacksof an unattractive appearance and taking up room in the bed even whennot in use.

Positioning the extended supplemental tailgate structure generallyperpendicularly to the plane of the main tailgate structure, while themain tailgate structure is moved to an open position such that the planeof the tailgate structure is substantially parallel to the bed of thepickup truck, places the extended supplemental tailgate structure in anorientation that is substantially parallel to the main tailgatestructure when the main tailgate structure is in a normal closedposition. In such an extended position, the supplemental tailgate canprovide a restriction to the rearward movement of objects located on thebed of the pickup truck. Furthermore, such an extended position of thesupplemental tailgate can provide support for objects placed on top ofthe supplemental tailgate.

Positioning the extended supplemental tailgate structure such that thesupplemental tailgate structure hangs below the plane of the maintailgate structure permits the cross member of the supplemental tailgateto be utilized as a step. In fact, U.S. Pat. No. 6,918,624, granted onJul. 19, 2005, teaches that the cross member of the supplementaltailgate apparatus can incorporate a flip-out step that enlarges thesurface of the underside of the cross member of the supplementaltailgate structure to enhance the use thereof as a step. Suchutilization of the supplemental tailgate apparatus assists the operatorin gaining physical access to the cargo area of the pick-up truck, whichis particularly helpful whenever the bed of the pick-up truck topositioned substantially above the ground surface.

Such a supplemental tailgate apparatus is preferably housed within theinterior of the main tailgate structure so that the supplementaltailgate apparatus is retracted into the interior of the main tailgatewhen not being utilized as either a step and/or as a cargo areaextension device, and, as a result, the main tailgate with a retractedsupplemental tailgate apparatus looks substantially the same as aconventional tailgate assembly. The conventional main tailgate assembly,however, because of internal structural members and the configuration ofthe conventional main tailgate assembly, cannot receive the movablesupplemental tailgate apparatus without undergoing some structuralmodifications.

Accordingly, it would be desirable to provide a main tailgate assemblyon a pick-up truck that would be capable of receiving a supplementaltailgate apparatus in a manner to allow the operation of thesupplemental tailgate apparatus in the various desired functions.

SUMMARY OF THE INVENTION

It is an object of this invention to overcome the aforementioneddisadvantages of the known prior art by providing structuralmodifications within the main tailgate structure to permit the mountingof a supplemental tailgate apparatus internally of the main tailgateassembly on a pick-up truck.

It is a feature of this invention that the main tailgate structure isprovided with a C-channel member or reinforcement member positioned atthe top or near the top of the main tailgate assembly to be engaged bythe inner and outer tailgate panels and provide structural support atthe top of the main tailgate assembly for the mounting of a supplementaltailgate apparatus.

It is an advantage of this invention that the C-channel member orreinforcement member may have a pair of upright legs that support,respectively, the inner and outer main tailgate panels.

It is another advantage of this invention that the upright legs of theC-channel member or reinforcement member are capable of engagement withthe inner and outer panels of the main tailgate structure throughwelding, riveting or a hemming process.

It is still another feature of this invention that the C-channel orreinforcement member may include a horizontal web member orientedorthogonally to the upright legs to permit the mounting of thesupplemental tailgate apparatus and increase section modulus.

It is another feature of this invention that the main tailgate assemblyhas at least one internal transverse reinforcement member spanningbetween and supporting the inner and outer panels of the main tailgateassembly.

It is still another feature of this invention that each internaltransverse support member is formed with a depression notch to permit aguide tube or the like to pass through the internal transverse supportmember.

It is yet another advantage of this invention that the guide tubes orthe like that receive the supplemental tailgate structure are detachablymounted by fasteners or the like to the main tailgate structure at boththe top and the bottom of the respective guide member.

It is yet another feature of this invention that each guide tube or thelike is affixed to a mounting bracket at the top of the guide tube topermit the detachable connection thereof to the C-channel member orreinforcement member at the top of the main tailgate assembly.

It is still another advantage of this invention that a mounting bracketfor supporting a grab handle mechanism may be incorporated into theinternal modifications around a guide tube to provide support for thedeployment of a grab handle to be utilized in conjunction withdeployment of the supplemental tailgate apparatus when being utilized asa step function.

It is a further advantage of this invention that the mounting bracketfor detachably connecting the guide tube to the C-channel can be weldeddirectly to the guide tube.

It is another object of this invention to provide a main tailgateassembly that will permit the receipt of and deployment of asupplemental tailgate apparatus from the interior of a main tailgateassembly while maintaining the conventional appearance of the maintailgate assembly for a pick-up truck.

It is still another object of this invention to support in a rigidmanner a supplemental tailgate apparatus within the interior of a maintailgate assembly without incurring rattles resulting from aninterfering supplemental tailgate apparatus.

It is a further object of this invention to provide a main tailgateassembly for use with a supplemental tailgate apparatus that is durablein construction, inexpensive of manufacture, carefree of maintenance,facile in assemblage, and simple and effective in use.

These and other objects, features and advantages are accomplishedaccording to the instant invention by providing a tailgate structuralconfiguration that accommodates the housing of a supplemental tailgateinternally within the tailgate. The tailgate is formed with an outerpanel and an inner panel to define an internal cavity. The upper portionof the tailgate includes a C-channel frame member or the like, such as areinforcement member, connected to both the inner and outer panels tosupport guide tubes housed in the supplemental tailgate. To enhancestructural stability, the tailgate further includes one or twotransversely oriented strainers having formed therein flangeddepressions or openings for the passage of the guide tubes verticallytherethrough. Each guide tube is affixed to a mounting bracket that isdetachably connected to the C-channel member or reinforcement member tosupport the guide tube within the tailgate. Positioning pins mounted onthe mounting bracket affixed to the guide tube engage locator holes inthe C-channel for positioning the supplemental tailgate.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages of this invention will become apparent upon considerationof the following detailed disclosure of the invention, especially whentaken in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of a tailgate for the cargo bed of apick-up truck incorporating the principles of the instant invention, theextendable supplemental tailgate apparatus being shown in phantomelevated above the tailgate assembly;

FIG. 2 is an elevational view of the tailgate assembly looking from theaspect of the outer panel with the outer panel being removed to depictthe internal structure of the tailgate assembly, the supplementaltailgate apparatus being shown in phantom in a partially raisedposition;

FIG. 3 is an elevational view of the tailgate assembly looking from theaspect of the inner panel with the inner panel removed to depict theinternal structure of the tailgate assembly;

FIG. 4 is a perspective view of the tailgate assembly with the innerpanel removed, as depicted in FIG. 3;

FIG. 5 is an enlarged partial top perspective detail view, taken fromthe aspect of the inner panel, of a guide tube mounted on the C-channeland received through the strainers for mounting at the bottom of thetailgate assembly, the mounting bracket for the optional grab handlebeing shown mounted to the C-channel;

FIG. 6 is an enlarged partial perspective detail view, taken from theaspect of the outer panel, of the C-channel and first strainer with themounting bracket for the optional grab handle depicted, the mountingbracket for the guide tube being shown in phantom exploded away from theC-channel;

FIG. 7 is an enlarged partial perspective detail view of the C-channel,guide tube and grab handle mounting bracket taken from the aspect of theinner panel;

FIG. 8 is an enlarged partial perspective detail view of the guide tubewith mounting bracket and the grab handle mounting bracket, with theC-channel being removed for purposes of clarity;

FIG. 9 is a top plan view of the C-channel member;

FIG. 10 is a upper perspective view of the central portion of theC-channel;

FIG. 11 is an enlarged elevational view of the guide tubes, mountingbrackets and latch striker with the C-channel, strainers and outer shellof the tailgate being shown in phantom: and

FIG. 12 is a perspective view of a pick-up truck cargo bed with thesupplemental tailgate assembly being lowered into the step function, arepresentative grab handle being shown in the deployed position inphantom.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-4, a tailgate assembly for pivotally mounting on apick-up truck cargo bed incorporates the principles of the instantinvention. Any left and right references are used as a matter ofconvenience and are determined by standing at the rear of the cargo bedwhere the tailgate is pivotally mounted and facing the cargo bed, thenormal direction of travel of the pick-up truck. The tailgate assembly10 is configured for the mounting of a supplemental tailgate apparatus20 of the type disclosed in U. S. Pat. No. 6,918,624, granted on Jul.19, 2005, to Scott Miller, et al, the contents of which are incorporatedherein by reference in its entirety. Furthermore, the supplementaltailgate apparatus 20 can have associated therewith an optional grabhandle device (not shown), which is disclosed in U. S. patentapplication Ser. No. 11/236,133, of Steve Bruford, et al, entitled “GrabHandle for Use with Supplemental Tailgate on Pick-Up Trucks”, now U.S.Pat. No. 7,090,276, granted on Aug. 15, 2006, the contents of which areincorporated herein in its entirety by reference.

As is best seen in FIG. 12, the pick-up truck T is conventionallymanufactured with a cargo bed 2 forming the rearward portion of thevehicle. The cargo bed 2 generally includes generally vertical, uprightside walls 3 having a floor member 4 extending generally horizontallytherebetween. The tailgate assembly 10 extends transversely above thefloor 4 between the side walls 3 at the rearwardmost portion of thecargo bed_2. The tailgate assembly 10 is pivotally mounted at the floor4 of the cargo bed 2 and is movable between an upright closed positionthat is oriented perpendicularly to the floor 4 and a lowered openposition that forms an extension of the floor 4 rearwardly of the sidewalls 3, as is depicted in FIG. 12.

A supplemental tailgate apparatus 20 of the type shown and described inU.S. Pat. No. 6,918,624 can be stored within the interior of thetailgate assembly 10 until deployed with the tailgate assembly 10lowered into the open position and the supplemental tailgate apparatus20 oriented generally vertically to serve as a substitute tailgate whilethe top surface of the lowered tailgate assembly 10 serves as anextension of the cargo bed. The supplemental tailgate apparatus 20 isalso pivotally movable into a lowered position such that the crossmember 22 is lower than the main tailgate structure. As is disclosed inthe aforementioned U.S. Pat. No. 6,918,624, the cross member 22 can alsoincorporate a flip-out step member (not shown) that enhances the use ofthe cross member 22 as a step.

With the supplemental tailgate 20 positioned below the main tailgatestructure 10 to perform the step function of the supplemental tailgate20, a user of the apparatus 20 can step upon the cross member 22, andany extended step member (not shown) if provided, and be assisted inmaking the next step on onto the inner panel 12(or top surface in theopen position) of the lowered tailgate assembly 10, thereby providingphysical access to the cargo bed and anything stored thereon. Accessonto the cargo bed may be facilitated by the use of a grab handleassembly (shown in phantom in FIG. 12) by which the person stepping ontothe cross member 22 of the lowered supplemental tailgate apparatus 20can be stabilized while ascending the supplemental tailgate 20 onto thetop surface of the lowered tailgate assembly 10. As disclosed in U.S.patent application Ser. No. 11/236,133, the grab handle assembly can bedeployed to assist a person descending from the main tailgate assembly10 to the surface of the ground through the use of the supplementaltailgate apparatus 20.

The supplemental tailgate apparatus 20 cannot be housed in aconventional tailgate as the enclosed structure of the tailgate will notallow the passage of the shaft or shafts connected to the cross member22 or the guide tubes 25, which preferably receive the shafts, throughthe interconnected inner and outer panels 12, 14 and internal strainers,or transverse support members, 15, 18. Furthermore, the conventionalassembled sheet metal tailgate assembly 10 would not have sufficientstructural support for the mounting of a supplemental tailgate apparatus20, particularly if used as a step function.

Referring to FIGS 1-11, the structural configuration of the tailgateassembly 10 is modified to include an upper frame support member, orreinforcement, preferably in the form of a C-channel 30, that extendstransversely at or near the top of the tailgate assembly 10. The innerand outer panels 12, 14 can be connected to the reinforcement member,preferably in the form of the C-channel 30, by welding or by a hemmingprocess in which the edges of the panel 12, 14 are folded over avertical edge of the structural frame member 30 and crimped thereto.Preferably, the inner panel 12 is welded to the inside upright leg 31 ofthe C-channel 30, while the outer panel 14 is hemmed over top of theoutside upright leg 33 of the C-channel 30. The lowermost web 34 of theC-channel 30 extending between the upright legs 31, 33 is orientedsubstantially horizontal (when the tailgate assembly 10 is in theclosed, upright position, and forms a U-shaped cross-sectionalconfiguration. The C-channel 30 is also formed with a flanged opening 36in the web 34 for each guide tube 25 utilized in the supplementaltailgate apparatus 20.

Preferably, the tailgate assembly 10 is formed with a pair oftransversely extending reinforcement members 15, 18, commonly referredto as “strainers”, although some conventional tailgates are formed withonly one strainer in the interior of the tailgate assembly 10.Preferably, the strainers 15, 18 are welded to the inner panel 12 andaffixed to the outer panel 14 through adhesives. To accommodate thevertical passage of the guide tubes 25 through the strainers 15, 18, thestrainers are formed with a flanged depression notch 16 to establish apassageway for the reception of the guide tube 25 therethrough. Theformation of flanges extending generally vertically (perpendicularly tothe major axis of the strainers 15, 18) minimizes scratching of theexterior coating placed on the guide tubes 25 while the guide tubes 25are being installed into the tailgate assembly 10, providing a lead-infeature for the installation of the guide tubes 25. The guide tubes 25can then pass from the C-channel 30 through the strainers 15, 18 to thebottom of the tailgate assembly where they can be detachably affixed bya bolt inserted through the hole 29. Alternatively, particularly if areinforcement member (strainer) is placed at or near the bottom of theguide tube 25, the guide tube 25 can be detachably connected to thestrainer to positionally fix the guide tube 25 within the tailgateassembly 10.

The top of each guide tube 25 is preferably affixed by welding to amounting bracket 26 that is oriented generally perpendicularly to thevertical axis of the guide tube 25. The mounting bracket 26 has anopening 27 that is alignable with the interior of the guide tube 25 andalignable with the opening 36 in the C-channel. The mounting bracket 26is also preferably formed with bolt holes 28 to permit the detachableconnection of the mounting bracket 26 to the C-channel. Once the guidetube 25 and mounting bracket 26 are connected, the guide tube 25 can beinserted through the opening 36 in the C-channel and passed through thedepression notches 16 in the strainers 15, 18 until the mounting bracketengages the web 34 of the C-channel. Connecting the mounting bracket 26to the C-channel 25 with removable bolts enables the guide tubes to beremovable for repair or replacement. The mounting bracket 26 includessupport members 40 for the pivoting and deployment of the telescopicsupport shafts 21 of the supplemental tailgate apparatus 20.

The C-channel 30 can also support a mounting bracket 38 that is boltedto the underside of the web 34 using the fasteners connecting thecorresponding mounting bracket 26 for the guide tube 25 to the topsurface of the C-channel web 34. The grab handle mounting bracket 38 canalso be bolted or welded to the top strainer 15. The grab handlemounting bracket 38 is formed in a manner to wrap around thecorresponding guide tube 25 so as to avoid interference therewith andsupports a mounting flange 39 for use in attaching and deploying thegrab handle, as is described in the aforementioned U.S. patentapplication Ser. No. 11/236,133.

The upper reinforcement member 30, as is best seen in FIGS. 9-11, alsoserves to mount a striker 44 for a latch mechanism (not shown) that isformed as part of the supplemental tailgate apparatus 20, which retainsthe supplemental tailgate apparatus 20 in the stored position within thetailgate assembly 10 until extension thereof is desired. The C-channel30 is also provided with locator holes 46, 48 adjacent to the flangedopenings 36 for the passage of the guide tubes 25 to be cooperable withNAB (no-adjust build) pins 49 that are detachably mounted on themounting bracket 26 and insertable within the locator holes 46, 48 tofacilitate the proper positioning of the supplemental tailgate apparatus20 for a flush fit with the exterior sheet metal of the tailgateassembly 10. Preferably, the NAB pins 49 are detachably fastened to themounting bracket 26 within an oversize hole to permit positionaladjustment thereof for proper seating and positioning of the NAB pin 49.

The modified tailgate assembly 10 is preferably formed by welding theinner panel 12 to the C-channel 30 and the strainers 15, 18. Theassembled guide tubes 25 with mounting brackets 26 can be insertedthrough the flanged openings 36 in the C-channel 30 and through theflanged notches 16 of the strainers 15, 18. Fasteners (not shown)connect the mounting bracket 26 to the web 34 of the C-channel 30. Thesesame fasteners (not shown) can also be used to mount the grab handlemounting bracket 38 to the underside of the web 34. An additionalfastener (not shown) can be utilized to secure the bottom end of theguide tubes to the inner panel 12, or via a bracket (not shown) that canmount on the lower strainer 18. After the guide tubes 25 are secured,the outer panel 14 can be mounted on the assembly 10, preferably byhemming the edges around the corresponding edges of the inner panel 12,the outside upright leg 33 of the C-channel 30, and other appropriateconventional mounting structure (not shown). Once the supplementaltailgate apparatus 20 is installed, the tailgate assembly 10 isavailable for mounting on the pick-up truck.

One skilled in the art will recognize that changes in the details,materials, steps and arrangements of parts which have been described andillustrated to explain the nature of the invention will occur to and maybe made by those skilled in the art upon a reading of this disclosurewithin the principles and scope of the invention. The foregoingdescription illustrates the preferred embodiment of the invention;however, concepts, as based upon the description, may be employed inother embodiments without departing from the scope of the invention.

For example, some pick-up truck tailgates are manufactured in a mannerthat a single piece of sheet metal is bent and folded to form both theinner and outer panels which can be joined at the top to establish theshell of the tailgate assembly defining the interior cavity thereof.Such tailgate configurations are intended to be encompassed within themodifications described herein. Furthermore, the upper frame support ispreferably a C-channel oriented into a U-shaped position; however, oneskilled in the art will understand that other formed frame supportmembers can be utilized to provide similar features. Similarly, thetailgate assembly can utilize one, two or more reinforcement members, orstrainers, within the interior of the tailgate shell.

1. A tailgate assembly pivotally mounted to a cargo bed of a pick-uptruck to be movable between a raised closed position and a lowered openposition, said tailgate assembly having an inner panel that is generallyplanar with said cargo bed when said tailgate assembly is in saidlowered open position and an outer panel defining an internal cavitytherebetween, said internal cavity housing a supplemental tailgateapparatus movable between a stored position and one or more operativepositions extended outwardly from said internal cavity, saidsupplemental tailgate apparatus including at least one elongated shaftretained within said internal cavity, comprising: a transverselyextending frame member located at a top portion of said tailgateassembly, said elongated shaft being received within said frame memberin register with an opening formed in said frame member; and atransversely extending reinforcement member positioned within saidinternal cavity below said frame member and being connected to both saidinner and outer panels, said reinforcement member being formed with apassageway therethrough for the vertical passage of said elongatedshaft, said passageway and said opening being aligned to receive saidelongated shaft of said supplemental tailgate apparatus and being formedwith flanges that extend in the direction of movement of said elongatedshafts.
 2. The tailgate assembly of claim 1 wherein said frame member isa C-channel oriented in a U-shaped orientation with a front upright leg,a rear upright leg and a generally horizontal web portion extendingtherebetween, said web portion having said flanged opening formedtherethrough to be registrable with said elongated shaft.
 3. Thetailgate assembly of claim 2 wherein said inner panel is welded to saidfront upright leg of said C-channel, said outer panel being hemmed ontosaid rear upright leg.
 4. The tailgate assembly of claim 2 wherein saidsupplemental tailgate apparatus is formed with a pair of elongatedshafts received through said C-channel and a pair of vertically spacedtransversely extending reinforcement members positioned between saidC-channel and a bottom portion of said tailgate assembly, each saidreinforcement member having a flanged passageway formed therein in analigned orientation for the passage of each of said elongated shafts. 5.The tailgate assembly of claim 2 wherein said C-channel is formed withlocator holes to receive a positioning pin mounted on said supplementaltailgate apparatus to control the positioning of said supplementaltailgate apparatus relative to said C-channel, said C-channel havingmounted thereon a striker for engagement with said supplemental tailgateapparatus to retain said supplemental tailgate apparatus in said storedposition.
 6. A tailgate assembly for pivotally mounting on a pick-uptruck for movement between an upright closed position and a lowered openposition, comprising: a shell having an inner panel and an outer panelspaced apart to define an internal cavity therebetween; a transverselyextending frame member connected to both said inner and outer panels ata top portion of said tailgate assembly, said frame member having anopening extending vertically therethrough; a mounting bracket detachablyconnected to said transversely extending frame member corresponding tosaid opening therein and having a passageway therein aligned with thecorresponding opening in said frame member, said mounting bracket beingattached to said transversely extending frame member; and a firsttransversely extending reinforcement member connected to both said innerand outer panels within said internal cavity below said frame member,said first support member being formed with a passageway in alignmentwith said opening in said frame member.
 7. The tailgate assembly ofclaim 6 wherein said frame member is formed as a C-channel with frontand rear upright legs and a horizontal web extending therebetween, saidfront upright leg being connected to said inner panel and said rearupright leg being connected to said outer panel.
 8. The tailgateassembly of claim 7 further comprising a second transversely extendingreinforcement member spaced vertically from said first support memberand being formed with a passageway in alignment with the passageway insaid first reinforcement member and the opening in said C-channel. 9.The tailgate assembly of claim 8 wherein each said passageway is formedas a depressed flanged notch into each corresponding said reinforcementmember, each said depressed flanged notch being open to said innerpanel.
 10. The tailgate assembly of claim 9 wherein said inner panel iswelded to said C-channel and to each said reinforcement member, saidouter panel being connected to said reinforcement members by adhesivesand hemmed around said rear upright leg of said C-channel.